How To Bleed 1987 Kawasaki EX500A Motorcycle Brakes

Bleeding the Front Brake on Your 1987 Kawasaki EX500A

Know Your EX500A’s Brake Layout

Before you open a bleeder, confirm what you are working on. The 1987 Kawasaki EX500A uses a hydraulic disc brake at the front wheel and a mechanical drum brake at the rear. That means the front system is the only one that contains brake fluid and the only one you bleed. The rear drum is operated by a rod or cable and is adjusted at the drum, not bled. This guide covers the front hydraulic circuit only. There is no ABS and no linked brake system on this model, so the procedure stays straightforward.

Why and When to Bleed the Front Brake

Brake fluid is hygroscopic, meaning it absorbs moisture from the air over time. Moisture lowers the fluid’s boiling point, and under hard or repeated braking that can lead to fade or a soft lever. Many riders refresh the fluid on a regular interval as preventive maintenance. Bleeding is also required whenever the hydraulic system has been opened: new brake lines, a caliper rebuild, master cylinder service, or any time air has entered. Symptoms that call for a bleed include a spongy or soft lever, a lever that pulls closer to the grip than it used to, dark or cloudy fluid in the reservoir, or a lever that feels inconsistent. If you see any of these, bleed the front brake before riding.

Tools and Supplies You Will Need

• Fresh brake fluid of the type marked on the master cylinder reservoir cap, from a sealed container
• A box-end wrench that fits the bleeder valve on the front caliper
• Clear tubing that fits snugly over the bleeder valve
• A small catch bottle for the old fluid
• Rags or shop towels
• A syringe or turkey baster for removing old fluid from the reservoir
• A screwdriver that fits the reservoir cap screws

A one-way check-valve bleeder or a vacuum bleeder can make the job easier if you are working alone, but the manual method works fine with a helper or with patience.

Prepare the Bike and Protect the Finish

Support the EX500A securely upright on a stand so the front wheel is off the ground and the handlebars can be turned. Turn the bars so the front master cylinder reservoir sits level; on this bike the reservoir is mounted on the handlebar, and a level reservoir lets you open the cap without spilling. Cover the fuel tank, the front fairing or instrument area, and any painted or plastic surfaces around the master cylinder and caliper with rags. Most brake fluid damages paint and plastic on contact, so wipe up any spill immediately and rinse the area with water.

Step-by-Step: Bleeding the Front Brake

1. Remove the reservoir cap and diaphragm. Use the syringe or turkey baster to draw most of the old fluid out of the reservoir, but do not let the reservoir run dry. Leave a small amount at the bottom so you do not push air into the master cylinder.
2. Fill the reservoir with fresh fluid from the sealed container, up to the level marking. Keep the container capped when not pouring.
3. Slide the clear tubing over the bleeder valve on the front caliper and route the other end into the catch bottle. Make sure the tubing fits snugly so air cannot be drawn in around it.
4. Fit the box-end wrench onto the bleeder valve. You will use it to open and close the valve while the lever is held.
5. Squeeze the front brake lever slowly and hold it against the grip. With the lever held, open the bleeder valve about a quarter turn. Fluid and air will flow through the tubing into the bottle. Close the bleeder valve before you release the lever. Releasing the lever with the bleeder open can draw air back into the caliper.
6. Release the lever slowly. Check the reservoir level and top it off with fresh fluid. Repeat the squeeze-hold-open-close-release sequence. Each time, watch the tubing for bubbles. Continue until the fluid coming through the tube is clean and free of bubbles, and the lever feels firm.
7. Keep the reservoir topped off throughout the process. If the reservoir runs low enough to draw air, you will have to start over and may need to bleed the master cylinder as well.
8. When you are satisfied, close the bleeder valve snugly with the box-end wrench. Do not overtighten it; snug is enough to seal. Remove the tubing and wipe the caliper area clean.

If your bike has two front calipers, bleed each one in turn, starting with the caliper farthest from the master cylinder. The EX500A normally has a single front caliper, so this does not apply unless the bike has been modified.

Finishing Up and Testing Before You Ride

Fill the reservoir to the correct level marking with fresh fluid. Reinstall the diaphragm and cap, making sure the diaphragm is seated properly. Clean any spilled fluid from the reservoir, caliper, and surrounding surfaces. Check for leaks at the bleeder valve and at the banjo fittings on the master cylinder and caliper. Before riding, pump the lever a few times and hold steady pressure. The lever should feel firm and consistent, not spongy, and it should not slowly sink toward the grip. Spin the front wheel to confirm the brake is not dragging. Test the brake at low speed in a safe area, such as a parking lot, before riding normally.

Troubleshooting and When to See a Shop

If the lever will not firm up after several bleeding attempts, or if it firms up only after pumping, air is still in the system. Persistent bubbles at the bleeder can mean the tubing is not sealing, the bleeder is being opened too far, or the master cylinder is drawing air. Fluid leaking from the master cylinder or caliper is a sign of a failed seal and should be repaired before riding. The home bleed is usually straightforward on this model. If you have opened the system and cannot get a firm lever after repeated attempts, or if you see fluid weeping from a component, stop and have a shop inspect the system. Brakes are safety-critical, and a lever that does not feel right is not ready for the road.

Related Shopping Categories

Shop Brake Fluid for a 1987 Kawasaki EX500A Motorcycle.

Shop Brake Lines for a 1987 Kawasaki EX500A Motorcycle.

Shop Brake Pads for a 1987 Kawasaki EX500A Motorcycle.

Shop Stands for a 1987 Kawasaki EX500A Motorcycle.

Shop Brake Tools for a 1987 Kawasaki EX500A Motorcycle.

Disclaimer: This guide is provided for general informational purposes only and is not intended to replace your motorcycle's official owner's manual. Always refer to your manufacturer's documentation for model-specific instructions, torque specifications, safety procedures, and maintenance requirements. If you are unsure or inexperienced, consider seeking assistance from a qualified mechanic or technician.